System and method for repairing or servicing a misting array assembly of an abatement system

ABSTRACT

Various methods and apparatus are disclosed that relate to one or more aspects of an abatement system that removes heat and/or one or more byproducts of combustion from a gas flow. In various aspects a misting array assembly is provided that includes at least one nozzle tubing having at least one nozzle coupled thereto.

CROSS-REFERENCE TO RELATED DOCUMENTS

This application is a continuation of currently pending application Ser.No. 12/787,243 filed May 25, 2010 and entitled Removable Misting ArrayAssembly for an Abatement System, which is hereby incorporated byreference in its entirety. This application is related to the followingco-pending Applications: application Ser. No. 12/787,372, filed May 25,2010 and entitled Misting Array Assembly Having Adjustable Nozzles;application Ser. No. 12/787,373, filed May 25, 2010 and entitled MistingArray Assembly Having Upwardly and Downwardly Disposed Nozzles;application Ser. No. 29/362,440 filed May 25, 2010 and entitled NozzleTubing Having Offset Nozzles; application Ser. No. 29/362,443, filed May25, 2010 and also entitled Nozzle Tubing Having Offset Nozzles;application Ser. No. 29/362,444, filed May 25, 2010 and entitled MistingArray Frame Structure; and application Ser. No. 29/362,442, filed May25, 2010 and entitled Sealing Structure for Blocking an Opening.

TECHNICAL FIELD

The present invention is directed generally to aspects of an abatementsystem. More particularly, various inventive methods and apparatusdisclosed herein relate to one or more aspects of an abatement systemsuch as, for example, a pollution abatement system or a system whichremoves heat and/or one or more byproducts of combustion from a gasflow.

BACKGROUND

Abatement systems function, generally, to remove heat and/or one or morepollutants from a stream of flue gas that is created by the combustionof one or more fuels. For example, a heat abatement system may remove,and optionally recover, heat from a stream of flue gas that is createdby the combustion of a hydrocarbon fuel. Also, for example, a pollutionabatement system may remove one or more pollutants from a stream of fluegas that is created by the combustion of a hydrocarbon fuel. Byproductsof hydrocarbon fuel combustion include one or more of nitrogen, carbondioxide, water, carbon monoxide, unburned hydrocarbons, oxides ofsulfur, mercury, particulates (e.g., soot) and oxides of nitrogen. Thecarbon monoxide, unburned hydrocarbons, oxides of sulfur, mercury,particulates, and oxides of nitrogen are often classified as pollutantsand may be subject to one or more governmental guidelines that regulatetheir control.

Many abatement systems make use of one or more misting arrays,optionally in combination with one or more condensing coils, to effectthe removal of heat and/or at least one targeted pollutant. One suchpollution abatement system is described in U.S. Pat. No. 6,344,177,which is hereby incorporated by reference in its entirety.

Generally speaking, the technology of U.S. Pat. No. 6,344,177 involvesremoving contaminants from flue gas by flowing the flue gas through afirst misting array, a first condensing coil, a second misting array,and a second condensing coil. Other abatement systems may utilizedifferent apparatus and methods for pollution abatement and/or heatrecovery or abatement.

Although current abatement systems allow for the removal of heat and/orone or more pollutants from a contaminated gas flow, many suffer fromone or more drawbacks. For example, abatement systems which employ oneor more misting arrays may not obtain desired coverage characteristicsfrom the misting array, may not employ misting arrays whose nozzleoutput is directionally adjustable, and/or may not employ misting arraysthat may be conveniently serviced or replaced. Moreover, other aspectsof the abatement system such as, for example, the intake and exhaustsystem, any condensing coil section present, and other structuralaspects of and methods related to the abatement system, may suffer fromone or more drawbacks. Thus, applicants have recognized and appreciatedthe need to improve various aspects of an abatement system.

SUMMARY

The present disclosure is directed to inventive methods and apparatusfor aspects of an abatement system, and, more specifically, one or moreaspects of an abatement system which removes heat and/or one or morebyproducts of combustion from a contaminated gas flow. For example, someaspects of the present disclosure are directed to a misting array of anabatement system, some aspects are directed toward a condensing coil ofan abatement system, some aspects are directed toward the intake and/orexhaust system of an abatement system, and other aspects are directed toother structural aspects of and methods related to an abatement system.

Generally, in one aspect, a misting array assembly disposed across anabatement chamber of an abatement system is provided. The abatementchamber has a gas flow extending therethrough moving in a gas flowdirection and the misting array assembly includes a sealing piece, aframe structure, a first nozzle tubing, and a second nozzle tubing. Thesealing piece has a first side and a second side opposite the firstside. The frame structure is coupled to the sealing piece and providedon the second side of the sealing piece. The first nozzle tubing extendsthrough the sealing piece and has a first nozzle tubing axis extendingsubstantially perpendicular to the direction of the gas flow. The firstnozzle tubing also has a first liquid source coupling and a plurality offirst tubing nozzles. The first liquid source coupling is on the firstside of the sealing piece and the first tubing nozzles are on the secondside of the sealing piece. The second nozzle tubing extends through thesealing piece and has a second nozzle tubing axis extendingsubstantially perpendicular to the direction of the gas flow. The secondnozzle tubing also has a second liquid source coupling and a pluralityof second tubing nozzles. The second liquid source coupling is on thefirst side of the sealing piece and the second tubing nozzles are on thesecond side of the sealing piece. The sealing piece, the framestructure, the first nozzle tubing, and the second nozzle tubing aremovable between an inserted position and a removed position. In theinserted position the frame structure, the first nozzle tubing, and thesecond nozzle tubing are in the abatement chamber and in the removedposition the frame structure, the first nozzle tubing, and the secondnozzle tubing are removed from the abatement chamber.

In some embodiments the second nozzle tubing is positioned with respectto the first nozzle tubing in a direction that is substantiallyperpendicular to the direction of the gas flow.

In some embodiments at least a portion of the first nozzle tubing isfixedly adjustable about the first nozzle tubing axis to a firstposition and a second position, whereby adjusting the first nozzletubing correspondingly adjusts the first tubing nozzles.

In some embodiments a plurality of the first tubing nozzles are providedat a first angular orientation relative to the first nozzle tubing axisand a plurality of the first tubing nozzles are provided at a secondangular orientation relative to the first nozzle tubing axis. In someversions of these embodiments the first angular orientation is offsetfrom the second angular orientation from ten to sixty degrees. In someversions of these embodiments the first angular orientation is offsetfrom the second angular orientation from thirty to fifty degrees. Insome versions of these embodiments the first angular orientation isoffset from the second angular orientation approximately forty degrees.

In some embodiments the frame structure includes at least one memberslidably engageable with corresponding track structure provided along atleast a portion of the inner periphery of the abatement chamber.

In some embodiments a portion of the outer periphery of the framestructure generally conforms to a portion of the inner periphery of theabatement chamber.

Generally, in another aspect a misting array assembly disposed across anabatement chamber of an abatement system is provided. The abatementchamber has a gas flow extending therethrough and the misting arrayassembly includes a sealing piece, a frame structure, a first nozzletubing, and a plurality of first tubing nozzles. The sealing piece has afirst side and a second side opposite the first side. The framestructure is coupled to the sealing piece and provided on the secondside of the sealing piece. At least a portion of the outer periphery ofthe frame structure engages structure within the abatement chamber. Thefirst nozzle tubing is coupled to the frame structure and extendsthrough the sealing piece. The first nozzle tubing has a liquid sourcecoupling on the first side of the sealing piece. The first tubingnozzles produce a nozzle output having a nozzle output central axis. Thefirst tubing nozzles are coupled to the first nozzle tubing on thesecond side of the sealing plate. The sealing piece, the framestructure, and the first nozzle tubing are slideably movable between aninserted position and a removed position. In the inserted position theframe structure, the first nozzle tubing, and the second nozzle tubingare in the abatement chamber and in the removed position the framestructure, the first nozzle tubing, and the second nozzle tubing areremoved from the abatement chamber.

In some embodiments a plurality of the first tubing nozzles are upwardlydisposed first tubing nozzles and a plurality of the first tubingnozzles are downwardly disposed first tubing nozzles. In some versionsof these embodiments the nozzle output central axis of each of theupwardly disposed first tubing nozzles is at a ten to thirty degreeupward angle with respect to the direction of the gas flow and thenozzle output central axis of each of the downwardly disposed firsttubing nozzles is at a ten to thirty degree downward angle with respectto the direction of the gas flow.

In some embodiments at least a portion of the first nozzle tubing isfixedly rotationally adjustable from at least a first position to asecond position, whereby adjusting the first nozzle tubingcorrespondingly adjusts the first tubing nozzles. In some versions ofthese embodiments the first nozzle tubing is linearly extending.

In some embodiments the frame structure includes at least one memberslideably engageable with corresponding track structure provided alongat least a portion of the inner periphery of the abatement chamber. Insome versions of these embodiments the at least one member includes aside member opposite the sealing piece, an upper member extendingbetween the sealing piece and the side member, and a lower memberopposite the upper member and extending between the sealing piece andthe side member.

In some embodiments the frame structure includes at least one trackstructure slidably engageable with a corresponding member provided alongat least a portion of the inner periphery of the abatement chamber.

Generally, in another aspect, a misting array section of an abatementsystem is provided. The misting array section includes an abatementchamber misting section and a misting array assembly. The abatementchamber misting section has an opposed top and bottom extending betweenan opposed first side and second side. The top and the bottom each hastrack structure extending therefrom. The first side has an openingtherethrough. The opening extends between the abatement chamber mistingsection and a shell of the abatement system and is in communication withthe track structure of the top and the bottom. The abatement chambermisting section has a gas flow extending therethrough. A majority of thegas flow moves in a gas flow direction. The misting array assembly isremovably received in the abatement chamber misting section and includesa sealing piece, a frame structure coupled to the sealing piece, nozzletubing coupled to the frame structure, and at least one nozzle coupledto the nozzle tubing. The sealing piece has a sealing plate engageableagainst the shell of the abatement system. The frame structure includesan upper frame member and a lower frame member slideably receivable inrespective track structure of the bottom and the top. The nozzle tubingextends through the sealing piece. The frame structure, the nozzletubing, and the nozzle are slideably removable from and slideablyinsertable in the abatement chamber.

In some embodiments the misting array section further includes a sidetrack structure extending from the second side and the frame structurefurther includes a side frame member extending between the upper framemember and the lower frame member and being slideably receivable in theside track structure.

In some embodiments the misting array section further includes a gasketinterposed between the sealing plate and the shell of the abatementsystem.

In some embodiments a plurality of the nozzle are provided, at leastsome thereof being upwardly disposed tubing nozzles. The nozzle outputcentral axis of each of the upwardly disposed tubing nozzles may be at afive to thirty degree upward angle counter to the direction of the gasflow.

In some embodiments some of the plurality of the nozzle are downwardlydisposed tubing nozzles. The nozzle output central axis of each of thedownwardly disposed tubing nozzles may be at a five to thirty degreedownward angle with the direction of the gas flow.

Generally, in another aspect, a misting array assembly disposed acrossan abatement chamber of an abatement system is provided. The abatementchamber has a gas flow extending therethrough and the misting arrayassembly includes a first nozzle tubing. The first nozzle tubing hasfirst tubing nozzles each producing a nozzle output having a nozzleoutput central axis. A plurality of the first tubing nozzles areupwardly disposed first tubing nozzles and a plurality of the firsttubing nozzles are downwardly disposed first tubing nozzles. The nozzleoutput central axis of each of the upwardly disposed first tubingnozzles is at a five to forty degree upward angle with respect to thedirection of the gas flow. The nozzle output central axis of each of thedownwardly disposed first tubing nozzles is at a five to forty degreedownward angle with respect to the direction of the gas flow. At leastone of the upwardly disposed first tubing nozzles is immediatelyneighbored on each side by at least one of the downwardly disposed firsttubing nozzles.

In some embodiments the upwardly disposed first tubing nozzles and thedownwardly disposed first tubing nozzles are alternatingly provided onthe first nozzle tubing.

In some embodiments the misting array assembly further includes a secondnozzle tubing having second tubing nozzles each producing a nozzleoutput having a nozzle output central axis, the second nozzle tubingbeing positioned with respect to the first nozzle tubing in a directionthat is perpendicular to the direction of the gas flow. In some versionsof these embodiments a plurality of the second tubing nozzles areupwardly disposed second tubing nozzles and a plurality of the secondtubing nozzles are downwardly disposed second tubing nozzles. The nozzleoutput central axis of each of the upwardly disposed second tubingnozzles may be at a five to forty degree upward angle with respect tothe direction of the gas flow and the nozzle output central axis of eachof the downwardly disposed second tubing nozzles may be at a five toforty degree downward angle with respect to the direction of the gasflow. In some versions of these embodiments the nozzle output centralaxis of each of the upwardly disposed second tubing nozzles may be at afifteen to twenty-five degree upward angle with respect to the directionof the gas flow and the nozzle output central axis of each of thedownwardly disposed second tubing nozzles may be at a fifteen totwenty-five degree downward angle with respect to the direction of thegas flow. In some versions of these embodiments the misting arrayassembly further includes a non-offset nozzle tubing between the firstnozzle tubing and the second nozzle tubing. The non-offset nozzle tubinghas a plurality of non-offset nozzles each producing a nozzle outputhaving a nozzle output central axis at a zero to five degree angle withrespect to the direction of the gas flow. In some versions of theseembodiments an output capacity of the non-offset nozzle tubing is atleast one-third less than an output capacity of the first nozzle tubingand less than an output capacity of the second nozzle tubing. In someversions of these embodiments the upwardly disposed second tubingnozzles and the downwardly disposed second tubing nozzles arealternatingly provided on the second nozzle tubing.

In some embodiments the nozzle output central axis of each of theupwardly disposed first tubing nozzles is directed counter to thedirection of the gas flow. In some versions of these embodiments thenozzle output central axis of each of the downwardly disposed firsttubing nozzles is directed counter to the direction of the gas flow.

Generally, in another aspect, a misting array assembly disposed acrossan abatement chamber of an abatement system is provided. The abatementchamber has a gas flow extending therethrough and the misting arrayassembly includes an adjustable first nozzle tubing, a plurality offirst tubing nozzles coupled to the first nozzle tubing, an adjustablesecond nozzle tubing, and a plurality of second tubing nozzles coupledto the second nozzle tubing. The adjustable first nozzle tubing has afirst nozzle tubing axis extending substantially perpendicular to thedirection of the gas flow. The first tubing nozzles each produce anozzle output having a nozzle output central axis. At least one of thefirst tubing nozzles is disposed at a first angular orientation and atleast one of the first tubing nozzles is disposed at a second angularorientation. The first angular orientation is offset from the secondangular orientation from five to sixty degrees. The first nozzle tubingis fixedly adjustable about the first nozzle tubing axis from at least afirst position to a second position, whereby adjusting the first nozzletubing correspondingly adjusts the first tubing nozzles. The secondnozzle tubing has a second nozzle tubing axis extending substantiallyperpendicular to the direction of the gas flow. At least a portion ofthe second nozzle tubing is fixedly adjustable about the second nozzletubing axis to a plurality of positions, whereby adjusting the secondnozzle tubing correspondingly adjusts the second tubing nozzles.

In some embodiments a plurality of alternating first tubing nozzles areprovided at the first angular orientation. In some versions of theseembodiments the first angular orientation is offset from the secondangular orientation ten to fifty degrees.

In some embodiments each of the second tubing nozzles is provided at acommon angular orientation relative to the second nozzle tubing axis.

In some embodiments the first position and the second position areoffset from one another at least five degrees about the first nozzletubing axis. In some versions of these embodiments the first nozzletubing is fixedly adjustable about the first nozzle tubing axis to aplurality of positions between the first position and the secondposition.

In some embodiments the misting array assembly further includes anindicator coupled to the first nozzle tubing and located exteriorly ofthe abatement chamber.

In some embodiments a majority of the nozzle output of each of thenozzles is directed with the direction of the gas flow.

In some embodiments the first nozzle tubing is adjustable exteriorly ofthe abatement chamber.

Generally, in another aspect a misting array assembly disposed across anabatement chamber of an abatement system is provided. The abatementchamber has a gas flow extending therethrough and the misting arrayassembly includes a sealing piece, a frame structure, a first nozzletubing, and a plurality of first tubing nozzles. The sealing piece has afirst side and a second side opposite the first side. The framestructure is coupled to the sealing piece and provided on the secondside of the sealing piece. The first nozzle tubing is coupled to theframe structure and extends through the sealing piece. The first nozzletubing also has a liquid source coupling on the first side of thesealing piece. The first tubing nozzles produce a nozzle output having anozzle output central axis and are coupled to a nozzle section of thefirst nozzle tubing on the second side of the sealing piece. A pluralityof the first tubing nozzles are upwardly disposed first tubing nozzlesand a plurality of the first tubing nozzles are downwardly disposedfirst tubing nozzles. The nozzle output central axis of each of theupwardly disposed first tubing nozzles is at a five to forty-five degreeupward angle with respect to the direction of the gas flow and thenozzle output central axis of each of the downwardly disposed firsttubing nozzles is at a five to forty-five degree downward angle withrespect to the direction of the gas flow.

In some embodiments the nozzle section of the first nozzle tubing islinearly extending.

In some embodiments the upwardly disposed first tubing nozzles and thedownwardly disposed first tubing nozzles are alternatingly provided onthe first nozzle tubing.

Generally, in another aspect an abatement system is provided. Theabatement system includes a gas flow inlet, an abatement chamber, a gasflow outlet, and a misting array assembly. The abatement chamber isdownstream of the gas flow inlet and incldues an abatement chambermisting section having an opening therethrough. The opening extendsbetween the abatement chamber misting section and a shell of theabatement system. The abatement chamber gas flow outlet is downstream ofthe abatement chamber misting section. The abatement chamber has a gasflow extending from the gas flow inlet to the gas flow outlet. Themisting array assembly is received in the abatement chamber mistingsection. The misting array assembly includes a sealing piece blockingthe opening, a frame structure coupled to the sealing piece andextending into the abatement chamber misting section, a nozzle tubingcoupled to the frame structure, and at least one nozzle coupled to thenozzle tubing. The nozzle tubing extends into the abatement chamber. Atleast a portion of the nozzle tubing is fixedly rotationally adjustablefrom exteriorly of the abatement system to a plurality of positions,whereby adjusting the nozzle tubing correspondingly adjusts the at leastone nozzle.

In some embodiments the nozzle tubing is rotationally adjustable to aplurality of fixed preselected positions.

In some embodiments the nozzle tubing is linearly extending.

In some embodiments the nozzle tubing is rotationally adjustable betweenat least a first position and a second portion that are rotationallyoffset at least ten degrees from one another.

In some embodiments a plurality of the nozzle are coupled to the nozzletubing. In some versions of these embodiments some of the plurality ofthe nozzle are upwardly extending and some of the nozzle are downwardlyextending.

In some embodiments the sealing piece includes a sealing plate. In someversions of these embodiments the sealing piece further includes asealing piece extension extending from the sealing plate into theopening.

In some embodiments the nozzle tubing extends through the sealing piece.

Generally, in another aspect a misting array assembly disposed across anabatement chamber of an abatement system is provided. The abatementchamber has a gas flow extending therethrough and the misting arrayassembly includes a sealing piece, a frame structure, a first nozzletubing, a plurality of first tubing nozzles, a second nozzle tubing, anda plurality of second tubing nozzles. The sealing piece has a first sideand a second side opposite the first side. The frame structure iscoupled to the sealing piece and provided on the second side of thesealing piece. At least a portion of the outer periphery of the framestructure engages structure within the abatement chamber. The firstnozzle tubing is coupled to the frame structure and extends through thesealing piece. The first nozzle tubing has a liquid source coupling onthe first side of the sealing piece and a nozzle section on the secondside of the sealing piece. The first tubing nozzles are coupled to thefirst nozzle tubing. The second nozzle tubing is coupled to the framestructure and extends through the sealing piece. The second nozzletubing has a second liquid source coupling on the first side of thesealing piece and a second nozzle section on the second side of thesealing piece. The second tubing nozzles are coupled to the secondnozzle tubing. The first nozzle section is independently fixedlyrotationally adjustable to a plurality of first nozzle sectionpositions, whereby adjusting the first nozzle section correspondinglyadjusts the first tubing nozzles. The second nozzle section isindependently fixedly rotationally adjustable from to a plurality ofsecond nozzle section positions, whereby adjusting the second nozzlesection correspondingly adjusts the second tubing nozzles.

In some embodiments a plurality of the first tubing nozzles are upwardlydisposed first tubing nozzles and a plurality of the first tubingnozzles are downwardly disposed first tubing nozzles. In some versionsof these embodiments the first nozzle section is linearly extending. Insome versions of these embodiments an upward nozzle output central axisof each of the upwardly disposed first tubing nozzles is at a ten tothirty degree upward angle with respect to the direction of the gas flowand a downward nozzle output central axis of each of the downwardlydisposed first tubing nozzles is at a ten to thirty degree downwardangle with respect to the direction of the gas flow.

In some embodiments the first nozzle section and second nozzle sectionare each independently rotationally adjustable to a plurality of fixedpreselected positions.

In some embodiments the first nozzle tubing and the second nozzle tubingare fixedly rotationally adjustable from a location on the first side ofthe sealing piece.

In some embodiments the first nozzle tubing includes an indicator on thefirst side of the sealing piece. In some versions of these embodimentsthe first side of the sealing piece includes a plurality of fiducialmarkings proximal the indicator.

Generally, in another aspect a misting array assembly disposed across anabatement chamber of an abatement system is provided. The abatementchamber has a gas flow extending therethrough and the misting arrayassembly includes a sealing piece, a frame structure, a first nozzletubing, and a second nozzle tubing. The sealing piece has a first sideand a second side opposite the first side. The frame structure iscoupled to the sealing piece and provided on the second side of thesealing piece. The first nozzle tubing is coupled to the frame structureand extends through the sealing piece. The first nozzle tubing has afirst nozzle tubing axis extending substantially perpendicular to thedirection of the gas flow. The first nozzle tubing also has a liquidsource coupling and a plurality of first tubing nozzles. The firstliquid source coupling is on the first side of the sealing piece and thefirst tubing nozzles are on the second side of the sealing piece. Thesecond nozzle tubing is coupled to the frame structure and extendsthrough the sealing piece. The second nozzle tubing has a second nozzletubing axis extending substantially perpendicular to the direction ofthe gas flow. The second nozzle tubing also has a liquid source couplingand a plurality of second tubing nozzles. The second liquid sourcecoupling is on the first side of the sealing piece and the second tubingnozzles are on the second side of the sealing piece. At least a portionof the first nozzle tubing and a portion of the second nozzle tubing areeach independently fixedly rotationally adjustable to a plurality ofpositions.

In some embodiments the second nozzle tubing is positioned with respectto the first nozzle tubing in a direction that is substantiallyperpendicular to the direction of the gas flow.

In some embodiments the first nozzle tubing includes a pipe nippleextending through the sealing piece. In some versions of theseembodiments the first nozzle tubing includes an adjustable coupling onan interior side of the sealing plate.

Generally, in another aspect an abatement system having at least oneremovable misting array assembly is provided. The abatement systemincludes an abatement chamber, a first misting array assembly, a firstcondensing coil, a second misting array assembly, a second condensingcoil, and a temporary replacement piece. The first misting arrayassembly is disposed in the abatement chamber. The first misting arrayassembly extends through a first misting array opening in the abatementchamber. The first misting array assembly includes a first sealing piecesealingly engaging the first misting array opening, a first framestructure coupled to the first sealing piece and disposed in theabatement chamber, and a first nozzle tubing having at least one firstnozzle coupled thereto. The first nozzle tubing is coupled to the firstsealing piece and the first frame structure and disposed in theabatement chamber. The first condensing coil is disposed in theabatement chamber downstream from the first misting array assembly. Thesecond misting array assembly is disposed in the abatement chamberdownstream from the first condensing coil. The second misting arrayassembly extends through a second misting array opening in the abatementchamber. The second misting array includes a second sealing piecesealingly engaging the second misting array opening, a second framestructure coupled to the second sealing piece and disposed in theabatement chamber, and a second nozzle tubing having at least one secondnozzle coupled thereto. The second nozzle tubing is coupled to thesecond sealing piece and the second frame structure and disposed in theabatement chamber. The second condensing coil is disposed in theabatement chamber downstream from the second misting array assembly. Atleast one of the first misting array assembly and the second mistingarray assembly is slidably and integrally removable from the abatementchamber, thereby exposing a respective one of the first opening and thesecond opening. The temporary replacement piece is sealingly engageblewith at least one of the first opening and the second opening when arespective of the first misting array and the second misting array isremoved from the abatement chamber.

In some embodiments the first misting array sealing piece includes asealing plate engageable over an exterior portion of the first opening.In some versions of these embodiments the temporary replacement piece issealingly engageable with the first opening and includes a temporarysealing plate engageable over an exterior portion of the first opening.In some versions of these embodiments the first misting array sealingpiece further includes a sealing piece extension extending from thesealing plate. The sealing piece extension is removably receivablewithin the first opening and optionally in substantially conforming fitwith the first opening. In some versions of these embodiments thetemporary replacement piece further includes a sealing piece extensionextending from the sealing plate. The sealing piece extension isremovably receivable within the first opening and optionally insubstantially conforming fit with the first opening.

In some embodiments both the first misting array assembly and the secondmisting array assembly are removable from the abatement chamber.

In some versions of these embodiments the temporary replacement piece issealingly engageable with both the first opening and the second openingwhen a respective of the first misting array and the second mistingarray is removed from the abatement chamber. In some versions of theseembodiments at least one of the first condensing coil and the secondcondensing coil is slideably removable from the abatement chamber.

In some embodiments the abatement system further includes a thirdmisting array assembly disposed in the abatement chamber downstream fromthe first misting array assembly.

In some versions of these embodiments the abatement system furtherincludes a third condensing coil disposed in the abatement chamberdownstream from the third misting array assembly. The third mistingarray assembly is optionally disposed in the abatement chamberdownstream from the second condensing coil.

In some embodiments the temporary replacement piece is coupled to thefirst frame structure and engages the first opening when the firstmisting array is removed from the abatement chamber.

Generally, in another aspect an abatement system having at least oneremovable misting array assembly is provided. The abatement systemincludes an abatement chamber, a first misting array assembly, a firstcondensing coil, and a temporary replacement piece. The first mistingarray assembly is disposed in the abatement chamber and extends througha first misting array opening in the abatement chamber. The firstmisting array assembly includes a first sealing piece sealingly engagingthe first misting array opening, a first frame structure disposed in theabatement chamber, and a first nozzle tubing having at least one firstnozzle coupled thereto. The first nozzle is disposed in the abatementchamber. The first temporary replacement piece is coupled to the firstframe structure interiorly of the abatement chamber and is sealinglyengageable with the first opening. A first condensing coil is disposedin the abatement chamber downstream from the first misting arrayassembly. The first misting array assembly is at least partiallyremovable from the abatement chamber. When the first misting arrayassembly is at least partially removed from the abatement chamber thefirst temporary replacement piece engages the first opening.

In some embodiments the first misting array sealing piece includes asealing plate engageable over an exterior portion of the first opening.

In some embodiments the first temporary replacement piece includes atemporary sealing plate engageable over the first opening.

In some embodiments the abatement system further includes a secondmisting array assembly disposed in the abatement chamber.

Generally, in another aspect, a method of servicing or replacing amisting array assembly of an abatement system while minimizing anyinterruption to the abatement system is provided. The method includesthe steps of: removing a first misting array assembly from an abatementchamber of the abatement system, thereby creating an opening between theabatement chamber and an exterior environment surrounding the abatementchamber; covering the opening with a temporary replacement piece;wherein the temporary replacement piece seals the opening; andmaintaining a second misting array assembly within the abatement chamberand operating at least the second misting array assembly and a fan ofthe abatement system during at least some of the time the opening iscovered with the temporary replacement piece.

In some embodiments the method further includes the step of uncoveringthe opening by removing the temporary replacement piece and placingeither the first misting array assembly or a replacement misting arrayassembly into the abatement chamber via the opening.

In some embodiments at least the second misting array assembly and thefan of the abatement system are operated during the entire time theopening is covered with the temporary replacement piece.

In some embodiments at least the second misting array assembly and thefan of the abatement system are operated during the entire time thefirst misting array is removed from the abatement chamber.

In some embodiments the temporary replacement piece is coupled to thefirst misting array interiorly of the abatement chamber.

It should be appreciated that all combinations of the foregoing conceptsand additional concepts discussed in greater detail below (provided suchconcepts are not mutually inconsistent) are contemplated as being partof the inventive subject matter disclosed herein. In particular, allcombinations of claimed subject matter appearing at the end of thisdisclosure are contemplated as being part of the inventive subjectmatter disclosed herein. It should also be appreciated that terminologyexplicitly employed herein that also may appear in any disclosureincorporated by reference should be accorded a meaning most consistentwith the particular concepts disclosed herein.

When reference is made herein to all or a portion of nozzle output beingdirected “counter” to the direction of a gas flow, it is intended onlythat the cited portion of nozzle output have a component of its velocitythat is directed counter to the gas flow. For example, if the gas flowis moving in a first direction along a first axis, it is intended thatnozzle output moving “counter” thereto have a component of its velocitythat is directed in a second direction (opposite the first direction)along the first axis. Accordingly, a portion of nozzle output that has avelocity component only in the second direction along the first axiswould be directed counter to the gas flow. Likewise, a portion of nozzleoutput that has a velocity component in the second direction along thefirst axis and also has a velocity component along a second axis that isperpendicular the first axis would also be directed counter to the gasflow.

Similarly, when reference is made herein to all or a portion of nozzleoutput being directed “with” the direction of a gas flow, it is intendedonly that the cited portion of nozzle output have a component of itsvelocity that is directed with the gas flow. For example, if the gasglow is moving in a first direction along a first axis, it is intendedthat nozzle output moving “with” the gas flow have a component of itsvelocity that is directed in the first direction along the first axis.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention.

FIG. 1 illustrates an upper access side and intake side perspective viewof a first embodiment of an abatement system.

FIG. 2 illustrates an upper access side and intake side perspective viewof the first embodiment of the abatement system with a first condensingcoil assembly and a second misting array assembly shown exploded awayfrom the abatement system in removed positions.

FIG. 3 illustrates a lower access side and exhaust side perspective viewof the first embodiment of the abatement system; portions of a shell andportions of an abatement chamber on an access side of the abatementsystem have been removed therefrom in order to provide a better view ofvarious components of the abatement system.

FIG. 4 illustrates an upper access side and exhaust side perspectiveview of the first embodiment of the abatement system; portions of ashell on an access side and a top of the abatement system have beenremoved and portions of an abatement chamber on an access side and a topof the abatement system have been removed in order to provide a betterview of various components of the abatement system.

FIG. 5 illustrates a perspective view of a first misting array of theabatement system of FIG. 1.

FIG. 6 illustrates an additional perspective view of the misting arrayof FIG. 5.

FIG. 7 illustrates an upper nozzle row of the misting array of FIG. 5.

FIG. 8A illustrates a section view taken along the section line 8A-8A ofFIG. 5 showing an upper nozzle tubing fixedly rotationally adjusted to afirst position.

FIG. 8B illustrates a section view similar to FIG. 8A, but showing theupper nozzle tubing fixedly rotationally adjusted to a second position;phantom lines of FIG. 8B depict nozzles of the upper nozzle tubing inthe first position of FIG. 8A.

FIG. 9 illustrates a close-up view showing a portion of a sealing pieceand a pipe nipple, a female tube fitting, and a nozzle section of anupper nozzle tubing of the first misting array of the first embodimentof the abatement system; portions of the pipe nipple, the female tubefitting, and the nozzle section of the nozzle tubing are shown insection.

FIG. 10 illustrates a close-up top section view of a portion of theabatement system taken along the section line 10-10 of FIG. 3; portionsof the sealing piece of the first misting array, the upper nozzle tubingof the first misting array, and the first misting array opening areshown.

FIG. 11 illustrates a close-up perspective view of the first embodimentof the abatement system showing the second misting array assemblyexploded away in a removed position; portions of a shell on an accessside and a top of the abatement system have been removed and portions ofan abatement chamber on an access side and a top of the abatement systemhave been removed in order to provide a better view of variouscomponents of the abatement system.

FIG. 12 illustrates a top perspective view of a fan and exhaust assemblyof the first embodiment of the abatement system.

FIG. 13 illustrates a top view of the fan and exhaust assembly of FIG.12; portions of an exhaust duct are broken away showing internalcomponents thereof.

FIG. 14 illustrates a close-up perspective view of the first embodimentof the abatement system showing the first condensing coil assemblyexploded away in a removed position; portions of a shell on an accessside and a top of the abatement system have been removed and portions ofan abatement chamber on an access side and a top of the abatement systemhave been removed in order to provide a better view of variouscomponents of the abatement system.

FIG. 15 illustrates a section view of the first embodiment of theabatement system taken along the section line 15-15 of FIG. 4.

FIG. 16 illustrates a second embodiment of a misting array for use in anabatement system.

FIG. 17 illustrates a portion of a third embodiment of a misting arrayfor use in an abatement system.

FIG. 18A illustrates a top section view of a portion of the thirdembodiment of the misting array of FIG. 17 shown inserted in a mistingarray opening.

FIG. 18B illustrates a section view of a portion of the third embodimentof the misting array of FIG. 17 taken along the section line 18B-18B ofFIG. 18A.

FIG. 19 illustrates a perspective view of a temporary replacement piece.

FIG. 20 illustrates a perspective view of a portion of a fifthembodiment of a misting array for use in an abatement system.

FIG. 21 illustrates a top section view of the fifth embodiment of themisting array of FIG. 20 taken along the section line 21-21 of FIG. 20.

FIG. 22 illustrates a top section view of the fifth embodiment of themisting array of FIG. 20 taken along the section line 22-22 of FIG. 20.

FIG. 23 illustrates a perspective view of a fourth embodiment of amisting array for use in an abatement system.

DETAILED DESCRIPTION

In the following detailed description, for purposes of explanation andnot limitation, representative embodiments disclosing specific detailsare set forth in order to provide a thorough understanding of theclaimed invention. However, it will be apparent to one having ordinaryskill in the art having had the benefit of the present disclosure thatother embodiments according to the present teachings that depart fromthe specific details disclosed herein remain within the scope of theappended claims. Moreover, descriptions of well-known apparatuses andmethods may be omitted so as to not obscure the description of therepresentative embodiments. Such methods and apparatuses are clearlywithin the scope of the claimed invention. For example, the aspects ofan abatement system disclosed herein are described in conjunction withan abatement system having a first misting array disposed in anabatement chamber, a first condensing coil downstream from the firstmisting array, a second misting array downstream from the firstcondensing coil, and a second condensing coil downstream from the secondmisting array. However, one or more aspects of an abatement systemdescribed herein may be implemented in abatement systems having otherconfigurations and implementation of the one or more aspects describedherein in alternatively configured abatement systems is contemplatedwithout deviating from the scope or spirit of the claimed invention.Also, for example, many aspects of an abatement system disclosed hereinare described in conjunction with an abatement system that abates bothheat and pollution from a gas stream. However, such aspects of anabatement system described herein may be implemented in abatementsystems that abate only heat or abate only pollution or any otherdesired component.

In FIG. 1 through FIG. 15 various aspects of a first embodiment of anabatement system 100 are shown. Referring initially to FIG. 1 throughFIG. 4, it is illustrated that the abatement system 100 includes asupport base 190 supporting a structure having a generallylongitudinally extending and generally rectangular shape. The supportbase 190 includes a plurality of lifting lugs 191 around the peripherythereof that may be utilized in lifting and placing the abatement system100 in a desired installation spot. The lifting lugs 191 may optionallybe removed once the abatement system 100 is placed in a desiredlocation.

The abatement system 100 also includes an air inlet opening 110 thatdefines an air inlet 111. The air inlet 111 generally defines thebeginning of an abatement chamber that extends interiorly through aportion of abatement system 100 and that will be described in additionaldetail herein. Air inlet 111 may be placed in communication with apolluted gas stream such as, for example, a flue gas stream containingat least one pollutant. For example, in some embodiments duct work maybe sealingly coupled to air inlet opening 110 and may carry a pollutedgas stream from a location remote from the abatement system 100 to theair inlet 111. The depicted abatement system 100 may, in someembodiments, be utilized to remove pollutants from a flue gas streamcreated by the combustion of natural gas.

An upper nozzle section 121A of an upper nozzle tubing, a middle nozzlesection 121B of a middle nozzle tubing, and a lower nozzle section 121Cof a lower nozzle tubing are provided adjacent the air inlet 111. Theupper, middle, and lower nozzle section 121A, 121B, and 121C form partof a first misting array 120, are provided in a downstream directionfrom the air inlet 111, and are disposed in a first misting section ofthe abatement chamber. The upper, middle, and lower nozzle tubinginclude, respectively, liquid source couplings 122A, 122B, and 122C,which are provided exteriorly of the abatement system 100. The liquidsource couplings 122A, 122B, and 122C may be coupled to tubing that isin communication with a water source, a water based solution source, orother liquid source. In some embodiments the liquid source couplings122A, 122B, and 122C may be half inch female tube fittings. In someembodiments the liquid source couplings 122A, 122B, and 122C may becoupled to tubing that is in communication with a liquid sourcecomprising water and/or hydrogen peroxide. In some embodiments the firstmisting array 120 may increase the relative humidity of gas flow movingthrough the first misting section to sixty to approximately one hundredpercent relative humidity.

Referring now to FIG. 5 through FIG. 10, various aspects of the firstmisting array 120 are illustrated and will be described in additionaldetail. The first misting array 120 includes a sealing piece 130 havinga sealing plate 132. The sealing piece 130 also optionally includes afirst sealing piece extension 135 extending rearwardly from the sealingplate 132. Vertically aligned handles 134 are coupled to the sealingpiece 130 and extend from a front face thereof. As will be described inadditional detail herein, the handles 134 may aid in the removal of thefirst misting array 120 from the abatement chamber.

A frame structure is coupled to the first sealing piece 130 and includesan upper frame structure member 141 having an upper frame structure rimportion 142 (shown in FIG. 6), a side frame structure member 145 havinga side frame structure rim portion 146, and a lower frame structuremember 143 having a lower frame structure rim portion 144. A middlesupport bar 148 of the frame structure extends vertically between theupper frame structure rim portion 142 and the lower frame structure rimportion 144. A side support bar 147 of the frame structure extends fromthe side frame structure rim portion 146 inwardly toward the middlesupport bar 148. The depicted frame structure is geometrically similarto the interior of the misting section of the abatement chamber. Also,as will be described herein in conjunction with a second misting array220, the upper frame structure member 141, the lower frame structuremember 143, and the side frame structure member 145 are configured toslidingly engage a corresponding track extending from portions of theabatement chamber when the misting array 120 is installed.

The upper nozzle section 121A of the upper nozzle tubing is coupled tothe sealing piece 130, is coupled to the middle support bar 148 via Uclamp 149A (FIG. 6), and is coupled to the side support bar 147 by a Uclamp (not shown). The upper nozzle section 121A also extends through anaperture provided through the side frame structure rim portion 146. Theupper nozzle section 121A is coupled to the sealing piece 130 via afemale tube fitting 124A that is coupled to a pipe nipple 123A on anabatement chamber side of the sealing piece 130. The pipe nipple 123Aextends through and is coupled to the sealing piece extension 135 andthe sealing plate 132 of the sealing piece 130. The pipe nipple 123A isalso coupled to the liquid source coupling 122A provided on an exteriorside of the sealing piece 130. A plug is provided at the end of uppernozzle section 121A distal its coupling with female tube fitting 124A.

In a similar manner as the upper nozzle section 121A, the middle nozzlesection 121B is coupled to the middle support bar 148 via a U clamp 149B(FIG. 6), is coupled to the side support bar 147 by a U clamp (notshown), and extends through an aperture provided through the side framestructure rim portion 146. The middle nozzle section 121B is coupled tothe sealing piece 130 via a female tube fitting 124B that is coupled toa pipe nipple 123B on an abatement chamber side of the sealing piece130. The pipe nipple 123B extends through and is coupled to the sealingpiece extension 135 and the sealing plate 132 of the sealing piece 130.The pipe nipple 123B is also coupled to the liquid source coupling 122Bprovided on an exterior side of the sealing piece 130. A plug isprovided at the end of middle nozzle section 121B distal its couplingwith female tube fitting 124B.

In a similar manner as the upper nozzle section 121A and the middlenozzle section 121C, the lower nozzle section 121C is coupled to themiddle support bar 148 via a U clamp 149C (FIG. 6), is coupled to theside support bar 147 by a U clamp (not shown), and extends through anaperture provided through the side frame structure rim portion 146. Themiddle nozzle section 121C is coupled to the sealing piece 130 via afemale tube fitting 124C that is coupled to a pipe nipple 123C on anabetment chamber side of the sealing piece 130. The pipe nipple 123Cextends through and is coupled to the sealing piece extension 135 andthe sealing plate 132 of the sealing piece 130. The pipe nipple 123C isalso coupled to the liquid source coupling 122C provided on an exteriorside of the sealing piece 130. A plug is provided at the end of thelower nozzle section 121C distal its coupling with female tube fitting124C. The use of caulking, gaskets, and/or welding may optionally beutilized at the juncture between the pipe nipples 123A, 123B, 123C, andthe openings through sealing piece 135 and/or the openings throughsealing plate 132 in order to ensure a satisfactory seal and/or toprevent rotational movement of the of the pipe nipples 123A, 123B, and123C.

The upper nozzle section 121A includes six upwardly disposed uppertubing nozzles 126A and six downwardly disposed upper tubing nozzles128A. The upwardly disposed upper tubing nozzles 126A and the downwardlydisposed upper tubing nozzles 128A are alternately provided on the uppernozzle section 121A. Each of the upwardly disposed upper tubing nozzles126A and each of the downwardly disposed upper tubing nozzles 128A is inflow communication with a liquid pathway extending through the interiorof upper nozzle section 121A, female tube fitting 124A, pipe nipple123A, and liquid source coupling 122A. Optionally, each of the upwardlydisposed upper tubing nozzles 126A and each of the downwardly disposedupper tubing nozzles 128A may be coupled to the liquid pathway withinupper nozzle tubing 121A using a full penetration weld.

Each of the upwardly disposed upper tubing nozzles 126A and each of thedownwardly disposed upper tubing nozzles 128A has a nozzle outputcentral axis that is directed counter to the direction of gas flowthrough the abatement chamber when the first misting array 120 isinstalled therein. In alternative embodiments one or more of theupwardly disposed upper tubing nozzles 126A and/or one or more of thedownwardly disposed upper tubing nozzles 128A may be positioned suchthat the nozzle output central axis thereof is directed with thedirection of the gas flow. The nozzle output central axis is an axisthat generally corresponds to the center of the nozzle output. Forexample, if the nozzle output was generally conical, the nozzle outputcentral axis would extend centrally from the tip of the cone to thecenter of the base of the cone. In the depicted embodiment, the nozzleoutput central axis of each upwardly disposed upper tubing nozzle 126Ais at approximately a forty degree angle with respect to a centraloutput axis of each of the downwardly disposed upper tubing nozzles128A.

When the female tube fitting 124A is sufficiently tightened, itcompresses against upper nozzle section 121A and thereby causes uppernozzle section 121A to be fixed at a given rotational orientation.Accordingly, the rotational orientation of the upper nozzle section 121Amay be fixed at a desired rotational orientation when tightening femaletube fitting 124A. Moreover, the female tube fitting 124A may besubsequently loosened, the rotational orientation of the upper nozzletubing adjusted, and the female tube fitting 124A retightened to therebyreadjust the rotational orientation of the upper nozzle section 121A.Adjusting the rotational orientation of the first nozzle section 121Aalso correspondingly adjusts the orientation of the upwardly disposedupper tubing nozzles 126A and the downwardly disposed upper tubingnozzles 128A with respect to the gas flow moving through the abatementchamber. Adjusting the rotational orientation of the upper nozzlesection 121A may allow for tuning of the misting output emitted from thenozzles 126A and 128A thereof in order to produce desired mistingquantity and/or saturation in one or more parts of the misting sectionof the abatement chamber. Also, the female tube fitting 124A may beloosened and upper nozzle section 121A removed to allow for cleaningand/or replacement of upper nozzle section 121A and/or nozzles 126A and128A thereof.

Referring to FIG. 8A, the upper nozzle section 121A is illustratedadjusted to a first rotational orientation. A central output axis 127Aof the visible upwardly disposed upper tubing nozzle 126A is atapproximately a forty degree angle with respect to a central output axis129A of the visible downwardly disposed upper tubing nozzle 128A. Thecentral output axis 127A is at approximately a twenty degree angle withrespect to the gas flow direction A and the central output axis 129A islikewise at an approximately twenty degree angle with respect to the gasflow direction A. The gas flow direction A is generally indicative ofthe direction of gas flow moving through abatement chamber when mistingarray 120 is in the installed position.

Referring to FIG. 8B, the upper nozzle section 121A is illustratedadjusted to a second rotational orientation. The phantom lines in FIG.8B depict the first rotational orientation of the upwardly disposedupper tubing nozzle 126A and the downwardly disposed upper tubing nozzle128A. In the second rotational orientation of FIG. 8B a central outputaxis 127A of the visible upwardly disposed upper tubing nozzle 126A isstill at approximately a forty degree angle with respect to a centraloutput axis 129A of the visible downwardly disposed upper tubing nozzle128A. The central output axis 127A is at approximately a fifteen degreeangle with respect to the gas flow direction A and the central outputaxis 129A is approximately at a twenty-five degree angle with respect tothe gas flow direction A. Accordingly, the second rotational orientationof the upper nozzle section 121A is offset approximately five degreeswith respect to the first rotational orientation. In alternativeembodiments the upper nozzle section 121A may optionally be fixed at anon-rotationally adjustable orientation.

Referring to FIG. 5 and FIG. 6, the middle nozzle section 121B includessix commonly oriented nozzles 125B. The commonly oriented nozzles 125Bare shown fixed at a rotational orientation such that the central outputaxes thereof are directed substantially directly counter to thedirection of gas flow within the abatement chamber when the mistingarray 120 is in the installed position. In alternative embodiments oneor more of the nozzles 125B may be positioned such that the nozzleoutput central axis thereof is directed with the direction of the gasflow. The rotational orientation of the middle nozzle section 121B (and,resultantly the commonly oriented nozzles 125B) may be adjusted in asimilar manner as described with respect to upper nozzle section 121Athrough loosening and tightening of female tube fitting 124B. Inalternative embodiments the middle nozzle section 121B may optionally befixed at a non-rotationally adjustable orientation.

The lower nozzle section 121C includes six upwardly disposed lowertubing nozzles 126C and six downwardly disposed lower tubing nozzles128C. The upwardly disposed lower tubing nozzles 126C and the downwardlydisposed lower tubing nozzles 128C are alternately provided on the lowernozzle section 121C. Each of the upwardly disposed lower tubing nozzles126C and each of the downwardly disposed lower tubing nozzles 128C has anozzle output central axis that is directed counter to the direction ofgas flow through the abatement chamber when the first misting array 120is in the installed position. In alternative embodiments one or more ofthe upwardly disposed lower tubing nozzles 126C and/or one or more ofthe downwardly disposed lower tubing nozzles 128C may be positioned suchthat the nozzle output central axis thereof is directed with thedirection of the gas flow. In the depicted embodiment the nozzle outputcentral axis of each upwardly disposed lower tubing nozzle 126C is atapproximately a forty degree angle with respect to a central output axisof each downwardly disposed lower tubing nozzle 128C. Also, in thedepicted embodiment the central output axis of each upwardly disposedlower tubing nozzle 126C and each downwardly disposed lower tubingnozzle 128C is at approximately a twenty degree angle with respect tothe gas flow within the abatement chamber when the misting array 120 isin an installed position. The rotational orientation of the lower nozzlesection 121C may be adjusted in a similar manner as described withrespect to upper nozzle section 121A through loosening and tightening offemale tube fitting 124C. In alternative embodiments the lower nozzlesection 121C may optionally be fixed at a non-rotationally adjustableorientation.

As shown for example in FIG. 5 and FIG. 6, a plurality of fastenerapertures are provided along the periphery of the exterior face of thesealing plate 132 and extend through the interior face of the sealingplate 132. The fastener apertures also extend through a gasket 136(shown in FIG. 5 and FIG. 10) provided along the periphery of the rearface of the sealing plate 132. As shown in FIG. 10, when the mistingarray 120 is placed in an inserted position, the gasket 136 abuts ashell of the abatement system 100. Fasteners may be inserted through thefastener apertures of the sealing plate 132 and received incorresponding receiving apertures in the shell of the abatement system100 to thereby sealingly and securely couple the sealing plate 132 overa first misting array opening 150 of the abatement system 100. Thegasket 136 may enhance the seal between the sealing plate 132 and theshell of the abatement system 100.

With continuing reference to FIG. 10, the first misting array opening150 of the abatement system 100 extends between the abatement chamberand the external environment when the misting array 120 is removed. Thefirst misting array opening 150 includes misting array opening sidewalls151 and 152. When the misting array assembly 120 is in the insertedposition (as depicted in FIG. 10) the sealing piece extension 135 is insubstantial conforming fit with the misting array opening 150. Inparticular, the sealing piece extension 135 is adjacent sidewalls 151and 152 and is substantially planar with a surface of the abatementchamber. Having the sealing piece extension 135 be in substantialconforming fit may prevent air from leaking in from and/or out throughthe first misting array opening 150 and/or may minimize turbulence ingas flow in the abatement chamber as it moves by the first misting arrayopening 150.

In some embodiments the nozzles 126A, 126C, 128A, 128C, and 125B ofmisting array 120 may be Model SP 1.0S1J nozzles available from ParkerHannifin Corp. (Cleveland, Ohio) having a flow rate of approximately0.72 GPM at 2000 PSI and having a solid cone shape distribution. In someembodiments approximately 0.95 to 1.58 GPM of liquid may be supplied tothe misting array 120. Other nozzles may of course be used and, ifnecessary, appropriate adjustments made to misting array 120 toaccommodate such other nozzles. In some embodiments the upper, middle,and lower nozzle sections 121A, 121B, and 121C may be half inch tubingwith a 0.065″ wall, the female tube fittings 124A, 124B, and 124C may behalf inch female tube fittings, and the pipe nipples 123A, 123B, and123C may be half inch NPT pipe nipples.

Although the first misting array 120 has been described in detailherein, one of ordinary skill in the art, having had the benefit of thepresent disclosure will recognize that other configurations of themisting array 120 may be utilized in other embodiments. For example,more or fewer nozzles may be provided on one or more of the nozzlesections. Also, for example, one or more portions of nozzle tubing maybe non-linear (e.g., curvate, circular, elliptical, curvilinear,rectangular, triangular), non-perpendicular with respect to the gas flowmoving through the abatement chamber, and/or may be non-parallel withrespect to other nozzle tubing. Also, for example, the angle of one ormore nozzles with respect to one or more other nozzles on a given nozzlesection may be unique from other nozzles on the nozzle section. Also,for example, if upwardly and downwardly disposed nozzles are provided ona nozzle section they may be non-alternatingly provided, may be providedwith some non-upwarldly and non-downwardly disposed nozzles, and/or mayeach be provided at a unique rotational angle about a nozzle section.Also, for example, the frame structure may be modified to interact withan abatement chamber having a different geometric configuration or mayhave a geometric structure that is non-conforming with an abatementchamber. Also, for example, the sealing piece 130 may be configured tointeract with a first misting array opening and/or a shell having adifferent configuration. For example, the sealing piece 130 may beconfigured to interact with one or more openings that extend through aside of an abatement system and also through the top of the abatementsystem. Also, for example, in some embodiments the size of the abatementchamber may be increased or decreased and the amount of nozzle tubing,nozzles, and/or arrangement of the nozzle tubing and/or nozzles may bealtered to provide a desired misting coverage. Also, for example, insome embodiments the nozzle tubing may comprise more or fewer pieces.Also, for example, the nozzle output central axis of one or more nozzlesmay be directed with the direction of gas flow through the abatementchamber when the misting array is inserted therein. Also, for example,the misting array and the abatement system may be configured forinsertion of the misting array into an opening through another side(e.g., the top) of the abatement system. Also, for example, in someembodiments the nozzle output central axis of one or more nozzles may bedirected with the direction of gas flow and the nozzle output centralaxis of one or more nozzles may be directed counter to the direction ofgas flow. Also, for example, in some embodiments the nozzle outputcentral axis of one or more nozzles on a nozzle tubing may be directedat an intersecting angle with respect to one or more nozzles on the samenozzle tubing.

Referring again to FIG. 1 through FIG. 4, downstream of the firstmisting array 120 is a first condensing coil assembly 160, which isshown exploded away from the abatement system 100 in a removed positionin FIG. 2. The first condensing coil assembly 160 may remove and/orrecover heat from gas flow within the abatement chamber. The firstcondensing coil assembly 160 includes condensing coils 161 supported bya coil frame 162. The condensing coils 161 are in communication with avent connection 163, a return connection 164, a supply connection 166,and a drain connection 166, all of which extend through openings in afirst condensing coil assembly sealing plate 167. The sealing plate 167includes vertically aligned handles 168 that, as will be described inadditional detail herein, may aid in the removal of the first condensingcoil assembly 160 from the abatement chamber. In some embodiments thecondensing coil frame 162, the condensing coils 161, and thecorresponding connections 163-166 may be Type CP Coils, Model No.CP-AL-36-54-6 Left, available from Aerofin Heat Transfer Products(Lynchburg, Va.). However, one of ordinary skill in the art having hadthe benefit of the present disclosure will recognize that othercondensing coils may be utilized in combination with the abatementsystem 100 described herein or with other abatement systems. When thecondensing coil assembly 160 is in the inserted position, as shown inFIGS. 1, 3, and 4, the condensing coils 161 are situated across the gasflow moving through the abatement chamber in a direction generallyperpendicular to the gas flow. The condensing coils 161 are positionedin a first condensing section of the abatement chamber when thecondensing coil assembly 160 is in the inserted position.

Referring to FIG. 14, a close-up perspective view of the abatementsystem 100 shows the first condensing coil assembly 160 in a removedposition. Portions of a shell on an access side of the abatement system100 and a top of the abatement system 100 and portions of the accessside and top side of the abatement chamber have been removed in order toprovide a better view of a condensing coil track structure within theabatement chamber. The track structure is accessible through a firstcondensing coil opening 170 that extends from the abatement chamber tothe external environment. The track structure includes a lower trackfront flange 171 and an opposed lower track rear flange 172; a sidetrack front flange 173 and an opposed side track rear flange 174; and anupper track front flange 175 and an opposed upper track rear flange 176.When the first condensing coil assembly 160 is inserted into the firstcondensing coil opening 170, the frame structure member 162 is guided bythe track structure. A stop plate 177 is optionally provided interposedbetween the lower track front flange 171 and the lower track rear flange172 to prevent the condensing coil assembly 160 from being inserted intothe abatement chamber beyond a certain depth.

As shown in FIG. 15, which shows the first condensing coil assembly 160in the inserted position, it can be seen that the track structure abutsand/or overlaps the frame structure member 162, thereby forcing asubstantial majority of the gas flow through the condensing coils 161.In other embodiments alternative track structure may be provided in theabatement chamber and configured to interact with coil frame 162 or acoil frame having an alternative construction than coil frame 162. Also,in some embodiments track structure may be integrated into the coilframe 162 and interact with a corresponding extension/blade or otherstructure extending from the abatement chamber.

As shown for example in FIG. 14, a plurality of fastener apertures areprovided along the periphery of the front face of the sealing plate 167and extend through the rear face of the sealing plate 167. The fastenerapertures also optionally extend through a gasket that may be providedalong the periphery of the rear face of the sealing plate 167. When thecondensing coil 160 is placed in an inserted position in the abatementchamber, the sealing plate 167 abuts a shell of the abatement system100. Fasteners may be inserted through the fastener apertures of thesealing plate 167 and received in corresponding receiving apertures inthe shell of the abatement system 100 to thereby sealingly and securelycouple the sealing plate 167 over the first condensing coil opening 170.The optional gasket may enhance the seal between the sealing plate 167and the shell of the abatement system 100.

Referring again to FIG. 1 and FIG. 2, interposed between the firstmisting array 120 and the first condensing coil assembly 160 is a firstaccess door 101A that enables access to portions of the abatementchamber between the first misting array 120 and the first condensingcoil assembly 160. In its closed position, the first access door 101Acreates a substantially sealed barrier between the abatement chamber andthe exterior environment. The first access door 101A may optionally beomitted in some embodiments. The first access door 101A and otherportions of the shell of the abatement system 100 are shown omitted fromFIG. 3 and FIG. 4 in order to provide a better view of internalcomponents of the abatement system 100 and their positioning within theabatement chamber. Portions of the abatement chamber are also omittedfrom FIG. 3 and FIG. 4.

Referring again to FIG. 1 through FIG. 4, downstream from the firstcondensing coil assembly 160 is a second misting array 220, which isshown exploded away from the abatement system 100 in a removed positionin FIG. 2. When a misting array (or one or more components of a mistingarray) is described herein as being in a removed position or beingremoved or removable from the abatement chamber, it does not require(but can include) that the misting array (or one or more components)actually be separated from the abatement system. Moreover, being in aremoved position or being removed or removable from the abatementchamber does not require (but can include) that the misting array (orone or more components) be completely removed from the abatementchamber. Rather, being in a removed position or being removed orremovable from the abatement chamber only requires that at least some ofthe misting array that is within the abatement chamber and in contactwith the gas flow of the abatement chamber when the misting array is inthe inserted position is at least partially removed from the gas flowwithin the abatement chamber. In the depicted embodiment the secondmisting array 220 shares the same configuration with misting array 120,but is simply in a different position within abatement system 100.Accordingly, description concerning many aspects of misting array 220 isomitted herein for purpose of conciseness. However, it is understoodthat those aspects of misting array 220 having numbering of 2XX share acommon configuration with those aspects of misting array 120 havingnumbering of 1XX. For example, sealing plate 232 has a commonconfiguration as sealing plate 132.

Although the first misting array 120 and second misting array 220 aredepicted and described herein as having a common configuration, it isunderstood that in alternative embodiments an abatement system may beprovided wherein a plurality of misting arrays are provided, and one ormore of the misting arrays may have a configuration that is distinct inone or more aspects from one or more other misting arrays of theabatement system. For example, one or more misting arrays may have moreor fewer nozzles than one or more other misting arrays, may have adifferent nozzle arrangement than one or more other misting arraysand/or may have a different frame structure than one or more othermisting arrays.

Referring now to FIG. 11, a close-up perspective view of the abatementsystem 100 shows the second misting array 220 in a removed position.Portions of a shell on an access side of the abatement system 100 and atop of the abatement system 100 and portions of an access and top sideof an abatement chamber have been removed in order to provide a betterview of a second misting array track structure within the abatementchamber. The second misting array track structure is accessible througha second misting array opening 250 that extends from the abatementchamber to the external environment when second misting array 220 is inthe removed position. The misting array opening 250 includes a firstsidewall 251 and opposed second sidewall 252, and a lower wall 253 andopposed upper wall 254. The misting array track structure includes alower track 257 having a lower track front flange and an opposed lowertrack rear flange; a side track 256 having a side track front flange andan opposed side track rear flange; and an upper track 255 having anupper track front flange and an opposed upper track rear flange. Whenthe second misting array 220 is inserted into the second misting arrayopening 250, the frame structure thereof is guided by the trackstructure extending from the abatement chamber. In particular, the upperframe structure member 241 is guided by the upper track 255, the lowerframe structure member 243 is guided by the lower track 257, and theside frame structure member 245 is engaged within the side track 256when the second misting array 220 is in the inserted position.

When the second misting array 220 is fully inserted, the upper track 255will overlap the upper frame structure member 241, the lower track 257will overlap the lower frame structure member 243, and the side track256 will overlap the side frame structure member 245. Accordingly, thesecond misting array 220 may be securely maintained in position and amajority of the gas flow through the second misting section theabatement chamber may be directed within the frame structure of thesecond misting array 220. In a similar manner as described with respectto the first misting array 120, when the second misting array 220 isplaced in an inserted position in the abatement chamber, the sealingplate 232 will abut a shell of the abatement system 100. Fasteners maybe inserted through the fastener apertures of the sealing plate 232 andreceived in corresponding receiving apertures in the shell of theabatement system 100 to thereby sealingly and securely couple thesealing plate 232 over the second misting array opening 250. A gasketmay optionally be interposed between the sealing plate 232 and the shellof the abatement system 100 to enhance the seal.

In the abatement system 100, first misting array track structure thatinteracts with frame structure of the first misting array 120 is alsoprovided in the abatement chamber. The first misting array trackstructure is accessible through the first misting array opening 150.Optionally, the first misting array track structure may include a lowertrack having a lower track front flange and an opposed lower track rearflange; a side track having a side track front flange and an opposedside track rear flange; and an upper track having an upper track frontflange and an opposed upper track rear flange. When the first mistingarray 120 is inserted into the first misting array opening 150, theframe structure thereof may be guided by the track structure extendingfrom the abatement chamber. Accordingly, in some embodiments both thefirst misting array 120 and the second misting array 220 may be slidablyremovable from the abatement system 100.

Although the track structures accessible through first misting arrayopening 150 and second misting array opening 250 have been described indetail herein and the frame structures of first and second mistingarrays 120 and 220 have also been described, one of ordinary skill inthe art, having had the benefit of the present disclosure will recognizethat other configurations of the track structure and/or frame structuremay be utilized. For example, in some embodiments alternative trackstructure may be provided through first misting array opening 150 andconfigured to interact with the same or alternative frame structure offirst misting array 120. Similarly, in some embodiments alternativetrack structure may be provided through second misting array opening 250and configured to interact with the same or alternative frame structureof second misting array 220. Also, for example, in some embodimentstrack structure may be integrated into the frame of first misting array120 and/or second misting array 220 and interact with a correspondingblade or other structure extending from the abatement chamber andaccessible through first misting array opening 150 and/or second mistingarray opening 250. Also, for example, the frame structure may bemodified to interact with an abatement chamber and/or track structurehaving a different geometric configuration. Also, for example, in someembodiments side track structure may be omitted.

Referring again to FIG. 1 through FIG. 4, downstream of the secondmisting array 220 is a second condensing coil assembly 260, which isshown partially exploded away from the abatement system 100 in apartially removed position in FIG. 2. In the depicted embodiment thesecond condensing coil assembly 260 shares a similar configuration withfirst condensing coil 160, but is simply in a different position withinabatement system 100. Accordingly, description concerning many aspectsof second condensing coil assembly 260 is omitted herein for the purposeof conciseness. However, it is understood that those aspects of secondcondensing coil assembly 260 having numbering of 2XX share a commonconfiguration with those aspects of first condensing coil assembly 160having numbering of 1XX. For example, sealing plate 267 has a commonconfiguration as sealing plate 167. Although first condensing coilassembly 160 and second condensing coil assembly 260 are depicted anddescribed herein as having a common configuration, it is understood thatin alternative embodiments an abatement system may be provided wherein aplurality of condensing coil assemblies are provided, and one or more ofthe condensing coil assemblies may have a configuration that is distinctin one or more aspects from one or more other condensing coil assembliesof the abatement system.

In the abatement system 100, second condensing coil track structure isprovided in the abatement chamber and is accessible through secondcondensing coil opening 270 (FIG. 4). Optionally, the second condensingcoil track structure may include a lower track front flange and anopposed lower track rear flange; a side track front flange and anopposed side track rear flange; and an upper track front flange and anopposed upper track rear flange. When the second condensing coilassembly 260 is inserted into the second condensing coil opening 270,the coil frame 262 thereof may be guided along the track structureextending from the abatement chamber. Accordingly, in some embodimentsboth the first condensing coil assembly 160 and the second condensingcoil assembly 260 may be slidably removable from the abatement system100.

When inserted in the abatement system 100, the second condensing coilassembly 260 is in a second condensing section of the abatement chamber.Moreover, the downstream side of the second condensing coil assembly 260is generally at the end of the abatement chamber. Referring to FIG. 3and FIG. 4, it is illustrated that a large opening end of a transitionpiece 188 is coupled to the end of the abatement chamber and a smallopening end of the transition piece 188 is coupled a fan entrance 182 ofa fan 180. The transition piece 188 acts as an intermediary structurebetween the larger abatement chamber and the smaller fan entrance 182.

As shown in FIG. 1 and FIG. 2, interposed between the second mistingarray 220 and the second condensing coil assembly 260 is a second accessdoor 101B that enables access to portions of the abatement chamberbetween the second misting array 220 and the second condensing coilassembly 260. In its closed position, second access door 101B creates asubstantially sealed barrier between the abatement chamber and theexterior environment. The second access door 101B may optionally beomitted in some embodiments. The second access door 101B and otherportions of the shell of the abatement system 100 portions of theabatement chamber are shown omitted from FIG. 3 and FIG. 4 in order toprovide a better view of internal components of the abatement system 100and their positioning within the abatement chamber.

With continuing reference to FIG. 1 through FIG. 4, and additionally toFIGS. 12 and 13, various aspects of the fan 180 and the exhaust assemblyof the abatement system 100 are described. The fan 180 is driven by amotor 181 and draws gas through air inlet 111 and through the abatementchamber when in operation. In some embodiments the fan 180 may be a Size271 ACF, Class 3, Arrangement-8SW, CCW BH fan available from The NewYork Blower Company (Willowbrook, Ill.) that operates at approximately13,500 CFM. One of ordinary skill in the art, having had the benefit ofthe present disclosure will recognize that other fans may be utilizedand that in other embodiments fans may be utilized that have a higher orlower CFM capability. For example, in some embodiments the abatementchamber may be increased in size and a fan having larger CFM capabilitymay be utilized.

The fan 180 also has a fan exhaust 183 that is coupled to an exhaustduct 184 and feeds gas flow received through fan entrance 182 to theexhaust duct 184. The fan 180, fan motor 181, and exhaust duct 184 aresituated in a fan and exhaust chamber of the abatement system 100. Theexhaust duct 184 is coupled to a transition piece 189 that defines anair outlet opening 112 (FIG. 3 and FIG. 4), which in turn defines an airoutlet 113 (FIG. 3 and FIG. 4). Referring to FIG. 13, the exhaust duct184 includes turning vanes 185A and 185B proximal its coupling with thefan exhaust 183. The turning vanes 185A and 185B extend from adjacentthe fan exhaust 183 to adjacent a straight portion of the exhaust duct184. The turning vanes 185A and 185B may help to transition exhaust fromthe fan to the straight portion of exhaust duct 184 and may preventexcess backpressure on the fan 180 and/or excess pressure on the exhaustduct 184. With continuing reference to FIG. 13 and additional referenceto FIG. 3 and FIG. 4, the exhaust duct 184 also includes turning vanes187A and 187B that extend from the end of the straight section ofexhaust duct 184 to the transition piece 189. The turning vanes 185A and185B may help to transition exhaust from the straight portion of exhaustduct 184 to the air outlet 113 and may prevent excess backpressure onthe fan 180 and/or prevent excess pressure on the exhaust duct 184. Thearrangement of the fan 180 and the exhaust duct 184 may enable theabatement system 100 to be constructed in a generally linearly extendingfashion.

Heat generated by the fan 180 and fan motor 181 is vented through a fanoutlet vent 103 (FIG. 1 through FIG. 4) provided between the fan andexhaust chamber and the exterior environment and is provided at the topof the abatement system 100. An outlet vent fan 104 (FIG. 3) is alsoincluded adjacent the fan outlet vent 103 to aid in the removal of heatfrom within the fan and exhaust chamber.

As shown in FIG. 1 and FIG. 2, third and fourth access doors 101C and101D enable access to the fan and exhaust chamber. The third access door101C includes an inlet vent 101C and the fourth access door 104Dincludes an inlet vent 101D to allow for external air to enter the fanand exhaust chamber. The third and fourth access doors 101C and 101D mayoptionally be omitted in some embodiments. The third and fourth accessdoors 101C and 101D, other portions of the shell, and portions of theabatement chamber of the abatement system 100 are shown omitted fromFIG. 3 and FIG. 4 in order to provide a better view of internalcomponents of the abatement system 100 and their positioning within theabatement chamber.

Referring to FIG. 4, FIG. 11, and FIG. 14, various drain inlets 193A-Care provided on the floor of the abatement chamber. A similar draininlet is provided adjacent the second condensing coil assembly 260, butis not shown in the figures. The floor of the abatement chamber issloped such that liquid is directed toward drain inlets 193A-C.Accordingly, liquid output from misting arrays 120 and 220 and/or liquidoutput from condensation on condensing coils 160 and 260 is directedtoward drain inlets 193A-C. The liquid may contain one or morepollutants captured therein from a flue gas stream moving through theabatement chamber. Referring to FIG. 3, tanks 194A-C are visible on thebase of the abatement system 100 surrounded by the support base 190. Thetanks 194A-C are in flow communication with respective of the draininlets 193A-C and collect liquid via the drain inlets 193A-C. Drainoutlets 195A-C extend from the tanks 194A-C and may be coupled to pipingthat leads to external tanks, external treatment areas, or elsewhere inorder to drain the tanks 194A-C. In some embodiments the tanks 194A-Cmay be omitted and the drain inlets 193A-C may be directly coupled toone or more piping that leads to external tanks, external treatmentareas, or elsewhere.

Optionally, one or more components within the abatement chamber of theabatement system 100 (e.g., the condensing coil assemblies 160/260, themisting arrays 120/220) and/or the abatement chamber itself may becoated with one or more coatings to protect from corrosion. For example,one or more components may be coated with one or more coatings availablefrom Heresite Protective Coatings (Manitowoc, Wis.).

Referring now to FIG. 16, a second embodiment of a misting array 320 foruse in an abatement system is illustrated. In some embodiments themisting array 320 may be utilized in an abatement system that removespollutants from a flue gas created by the combustion of coal. Themisting array 320 is similar to the first misting array 120 and thesecond misting array 220, but does not include a middle nozzle row. Themisting array 320 includes a sealing piece 330 having a sealing plate332 and a sealing plate extension 335. Two handles 334 are provided onan exterior face of the sealing plate 332. A frame structure is coupledto and extends from the sealing piece 330 and includes an upper framestructure member 341 having an upper frame structure rim portion (notshown), a side frame structure member 345 having a side frame structurerim portion 346, and a lower frame structure member 343 having a lowerframe structure rim portion 344. The frame structure also includes amiddle support bar 348 and a side support bar 347.

An upper nozzle tubing of the misting array 320 has an upper liquidsource coupling 322A on the exterior side of the sealing piece 330,extends through the sealing piece 330, and has an upper nozzle section321A on an interior side of the sealing piece 330. The upper nozzlesection 321A has a plurality of upwardly disposed nozzles 326A anddownwardly disposed nozzles 328A coupled thereto. The upwardly anddownwardly disposed nozzles 326A and 328A are alternatingly provided onthe upper nozzle section 321A and are offset approximately forty degreesfrom one another. Similarly, a lower nozzle tubing of the misting array320 has a lower liquid source coupling 322C on the exterior of thesealing piece 330, extends through the sealing piece 330, and has alower nozzle section 321C on an interior side of the sealing piece 330.The lower nozzle section 321C has alternatingly provided upwardly anddownwardly disposed nozzles 326A and 328A that are offset approximatelyforty degrees from one another.

Referring now to FIG. 17, FIG. 18A, and FIG. 18B, aspects of a thirdembodiment of a misting array 420 for use in an abatement system aredepicted and described. FIG. 17 depicts portions of the sealing piece430 of the misting array 420. The sealing piece 430 includes a sealingplate 432 having vertically aligned handles 434 thereon. Liquid sourcecouplings 422A, 422B, and 422C of upper, middle, and lower nozzletubings, respectively, are provided on an exterior side of sealing plate432. Indicators 438A, 438B, and 438C are coupled to pipe nipples 423A,423B, and 423C of upper, middle, and lower nozzle tubing proximalrespective of liquid source couplings 422A, 422B, and 422C. Fiducialmarkings 439A, 439B, and 439C are provided on the sealing plate 432proximal respective of the indicators 438A, 438B, and 438C. Thepositioning of the indicators 438A, 438B, and 438C with respect to thefiducial markings 439A, 439B, and 439C is indicative of the rotationalorientation of respective nozzle tubing coupled to the indicators 438A,438B, and 438C. For example, the positioning of the indicator 438A maybe indicative that the upper nozzle tubing coupled to the indicator 438Ais at a first rotational orientation. The positioning of the indicator438B may be indicative that the middle nozzle tubing coupled to theindicator 438B is at a second rotational orientation offsetapproximately twenty-five degrees from the first rotational orientationof the upper nozzle tubing.

In the depicted embodiment, the rotational orientation of respectivenozzle tubing coupled to the indicators 438A, 438B, and 438C may beadjusted from exteriorly of the sealing piece 430. Referring to FIG.18A, a top section view of a portion of the misting array 420 is shownwith the misting array 420 inserted into an opening 450 of an abatementsystem. The opening 450 includes opposed sidewalls 451 and 452 andprovides access to an abatement chamber. Portions of the upper nozzletubing of the misting array 420 are visible in FIG. 18A. The uppernozzle tubing includes a pipe nipple 423A coupled to the liquid sourcecoupling 422A. The pipe nipple 423A extends through the sealing plate432 and the sealing piece extension 435 of the sealing piece 430. Agasket 405 is provided around pipe nipple 423A and sealingly engages anopening of sealing piece extension 435 through which pipe nipple 423Aextends. A portion of the pipe nipple 423A between the sealing pieceextension 435 and a female tube fitting 424A of the upper nozzle tubingis sized so as to engage the gasket 405 and thereby cause the gasket 405to sealingly engage the opening of sealing piece extension 435.

An open coil spring 406 is interposed between an engagement washer 407and an interior side of an abatement chamber facing wall of the sealingpiece extension 435. The open coil spring 406 exerts force on theengagement washer 407 and the interior side of the abatement chamberfacing wall of the sealing piece extension 435. The engagement washer407 is provided around and fixedly coupled to the pipe nipple 423A. Theengagement washer 407 includes an engagement protrusion 407A extendingtherefrom that releasably engages a keyed rotational restraint mechanism408 that is coupled to an interior wall of the sealing plate 432. Asection view of the engagement washer 407, rotational restraintmechanism 408, and pipe nipple 423A along the section line 18B-18B ofFIG. 18A is shown in FIG. 18B. The rotational restraint mechanism 408includes a plurality of notches radially arranged thereon that are sizedto receive and substantially lock into place engagement protrusion 407A.Accordingly, engagement protrusion 407A may be locked into a desired ofa plurality of preselected positions defined by the notches of restraintmechanism 408. When engagement protrusion 407A is locked into a notch ofthe restraint mechanism 408, the rotational orientation of the washer407, the pipe nipple 423A, and the remainder of the nozzle tubing(including attached nozzles) is also locked into place.

In order to adjust the notch of restraint mechanism 408 in whichengagement protrusion 407A is locked, a user may first cause force to beapplied on pipe nipple 423A from exteriorly of the sealing plate 432 ina direction along the central axis of pipe nipple 423A. The force needsto be of a magnitude sufficient to compress spring 406 enough to causethe protrusion 407A to be disengaged from the restraint mechanism 408.The upper nozzle tubing may be coupled to a frame of misting arrayassembly 420 in such a manner as to allow sufficient translation thereofto enable the protrusion 407A to be disengaged from the restraintmechanism 408. Once force in a direction along the central axis of pipenipple 423A is applied, the user may continue to apply such force andcause pipe nipple 423A (and the remainder of the upper nozzle tubing) tobe rotated in a desired direction from exteriorly of the sealing plate432. When the upper nozzle tubing is rotated to a desired orientation,the force in a direction along the central axis of pipe nipple 423A maybe released to cause the protrusion 407A to engage a notch of therestraint mechanism 408. The force of the spring 406 will lock theprotrusion 407A in place and will also cause a portion of the pipenipple 423A to reengage the gasket 405 and thereby ensure the gasket 405sealingly engages the opening through sealing plate extension 435.Slight tuning of the rotational orientation of the upper nozzle tubingmay be necessary to cause the protrusion 407A to engage a notch of therestraint mechanism 408 (and not adjacent structure). In someembodiments the structure bordering the notches of restraint mechanism408 and/or the protrusion 407A may be chamfered to help memberprotrusion 407A into a proximal adjacent notch. In some embodiments thefiducial markings 439A may be substantially aligned with notches ofrestraint mechanism 408 to aid in the rotational alignment of the uppernozzle tubing. Middle nozzle tubing and lower nozzle tubing of mistingarray 420 may optionally employ similar push and turn rotationaladjustment structure described with respect to upper nozzle tubing ofmisting array 420. In some embodiments gasket 405 may be replaced orsupplemented with other sealing structure. For example, in someembodiments dual bellows type carbon seals may be utilized. For example,a first bellows type carbon seal may be provided around and coupled tothe pipe nipple 423A on an abatement chamber side of sealing pieceextension 435 adjacent to sealing piece extension 435. A second bellowstype carbon seal may be provided coupled to sealing piece extension 435around the opening provided through the sealing piece extension 435. Thefirst and second bellows type carbon seals maybe in sealing engagementwhen the protrusion 407A is engaging a notch of the restraint mechanism408 and may be separated from one another when the spring 406 issufficiently compressed.

Referring now to FIG. 19, a perspective view of a temporary replacementpiece 530 for use in an abatement system is shown. The temporaryreplacement piece 530 may be utilized in the first abatement system 100and may block either of first misting array opening 150 or secondmisting array opening 250 when respective of first misting array 120 orsecond misting array 220 is removed therefrom. The temporary replacementpiece is structurally similar to sealing pieces 130 and 230 and includesa sealing plate 532, a sealing plate extension 535, and a plurality ofhandles 534 vertically arranged on an exterior face of the sealing plate532.

The temporary replacement piece 530 may be utilized when servicingand/or replacing one of the misting arrays 120 and 220. One of themisting arrays 120 or 220 may be removed from the abatement chamber ofthe abatement system 100, thereby exposing a respective of the mistingarray openings 150 or 250. One of the misting array openings 150 or 250may then be covered with the temporary replacement piece 530. Thetemporary replacement piece 530 will seal the respective array opening150 or 250. Fasteners may optionally be inserted in fastener aperturesthrough the sealing plate 532 and received in corresponding apertures ofthe abatement system 100 to securely couple the sealing piece 530 overthe misting array opening 150 or 250. While the temporary replacementpiece 530 is in place and one of the misting arrays 120 or 220 removed,the abatement system 100 may continue to be operated with only one ofthe misting arrays 120 or 220 being in operation. Optionally, the amountof fluid input to the remaining of misting arrays 120 or 220 may beincreased during such time period. The removed of misting arrays 120 or220 may optionally be cleaned, repaired, and/or replaced with anothermisting array. When the cleaned, repaired, or replacement misting arrayis ready to be reinserted into the abatement chamber the temporaryreplacement piece 530 may be removed from the opening 150 or 250 toenable reinsertion. Optionally, the abatement chamber 100 may continueto operate during the entire time that one of the misting array openings150 or 250 is removed or only during portions of such time (e.g., duringthe time that one of the misting array openings 150 or 250 is removedand temporary replacement piece 530 is in place over a respective ofopenings 150 or 250).

Referring now to FIG. 23, a fourth embodiment of a misting array 720 foruse in an abatement system is depicted and described. The misting array720 includes a sealing piece 730 having a sealing plate 732 and asealing plate extension 735. Two handles 734 are provided on an exteriorface of the sealing plate 732. A frame structure is coupled to andextends from the sealing piece 730 and includes an upper frame structuremember 741 having an upper frame structure rim portion (not shown), aside frame structure member 745 having a side frame structure rimportion 746, and a lower frame structure member 743 having a lower framestructure rim portion 744. The frame structure also includes a middlesupport bar 748 and a side support bar 747.

An upper nozzle tubing of the misting array 720 has an upper liquidsource coupling 722A on the exterior side of the sealing piece 730,extends through the sealing piece 730, and has a plurality of upwardlydisposed nozzles 726A and downwardly disposed nozzles 728A coupledthereto. Similarly, a middle nozzle tubing has a middle liquid sourcecoupling 722B on the exterior side of the sealing piece 730, extendsthrough the sealing piece 730, and has a plurality of upwardly disposednozzles 726B and downwardly disposed nozzles 728B coupled thereto.Similarly, a lower nozzle tubing of the misting array 720 has a lowerliquid source coupling 722C on the exterior of the sealing piece 730,extends through the sealing piece 730, and has a plurality of upwardlydisposed nozzles 726C and downwardly disposed nozzles 728C coupledthereto.

A temporary replacement piece 732B is coupled to the side framestructure member 745 of the frame structure of the misting array 720.The temporary replacement piece 732B is substantially similar to sealingplate 732 and includes a gasket 736B on an engagement surface thereof.The temporary replacement piece 732B may be coupled to the framestructure member 745 after portions of the misting array 720 have beeninserted into an opening of an abatement chamber. When the misting array720 is fully inserted in the abatement chamber the temporary replacementpiece 732B may be proximal a wall of the abatement chamber that isopposite the opening through the abatement chamber. When the mistingarray 720 is removed from the abatement chamber the temporaryreplacement piece 732B will sealingly engage the opening through theabatement chamber from inside the abatement chamber. The misting array720 may be repaired or replaced while the misting array 720 is removedand the temporary replacement piece 732B is covering the opening throughthe abatement chamber. The temporary replacement piece 732B mayoptionally include one or more apertures that receive fasteners insertedthrough apertures through the abatement system 100. The temporaryreplacement piece 732B may also optionally include one or more notches709 at the top short end thereof and/or the bottom short end thereof.The one or more notches 709 may be sized to interface with trackstructure within the abatement chamber to thereby enable the temporaryreplacement piece 732B to move without substantial interference from thetrack structure.

Referring now to FIG. 20 through FIG. 22, aspects of a fifth embodimentof a misting array for use in an abatement system are depicted anddescribed. Portions of a sealing piece 630 of the misting array areillustrated and include a sealing plate 632 having a handle 634 thereon.A sealing piece extension 635 extends rearwardly from the sealing plate632. Portions of a nozzle tubing of the misting array are alsoillustrated. The nozzle tubing includes a first inline swivel coupled tothe liquid source coupling 622. The first inline swivel includes a firstportion 696A and a second portion 696B that are rotationally adjustableand sealed with respect to one another. The first portion 696A includesa male connection threadedly and sealingly coupled to the liquid sourcecoupling 622. The second portion 696B includes a female connectionthreadedly and sealingly coupled to a pipe nipple 623. The pipe nipple623 extends through a journal 698 that is extending through an openingin the sealing plate 632. The pipe nipple 623 is sealingly coupled tothe journal 698 via a compression nut 699 threadedly received by thejournal 698. The journal 698 is sealingly coupled to a first portion697A of a second inline swivel that is rotationally adjustable withrespect to a second portion 697B of the second inline swivel. The secondportion 697B of the second inline swivel extends through an opening inthe sealing piece extension 635 and is seal welded to the openingthrough sealing piece extension 635. The pipe nipple 623 extends throughthe second inline swivel and is coupled to a female tube fitting 624which, in turn, is coupled to a nozzle section 621. An upwardly disposednozzle 626 is visible in FIG. 22 extending from the nozzle section 621.

The journal 698 is selectively rotatable within the opening through thesealing plate 632. The journal 698 is coupled to an adjustment plate 606having an aperture therethrough. The aperture through the adjustmentplate 606 has a screw extending therethrough. The screw is coupled tothe sealing plate 632 and removably receives an adjustment lock down nut607. When the adjustment lock down nut 607 is sufficiently tightened,thereby compressing adjustment plate 606, the journal 698 is restrainedfrom rotating within the opening through the sealing plate 632. However,when the adjustment lock down nut 607 is loosened, the journal 698 mayrotate freely within the opening through the sealing plate 632.Accordingly, loosening the lock down nut 607 allows the second portion696B of the first inline swivel, the pipe nipple 623, the compressionnut 699, the journal 698, the first portion 697A of the second inlineswivel, the female tube fitting 624, and the nozzle section 624 to allrotate in unison. The aforementioned elements will all be rotated inunison since they are all coupled to one another. Moreover, the couplingbetween the aforementioned elements, along with the seal welding betweenthe second portion 697B of the second inline swivel and the sealingpiece extension 635, ensures a seal may be maintained between anabatement chamber and an external environment. The embodiment of FIG. 20through FIG. 22 enables rotation of the nozzle tubing from exteriorly ofan abatement system while maintaining a seal between an abatementchamber and the external environment.

An indicator 638 extends from adjustment plate 606 and is proximalfiducial markings 639 provided on a plate interposed between adjustmentplate 606 and sealing plate 632. The positioning of the indicator 638with respect to the fiducial markings 639 is indicative of therotational orientation of the nozzle tubing. In some embodiments theinline swivels may be Series 006 Inline Swivels with Bushings availablefrom Rotary Systems, Inc. (Minneapolis, Minn.).

While several inventive embodiments have been described and illustratedherein, those of ordinary skill in the art will readily envision avariety of other means and/or structures for performing the functionand/or obtaining the results and/or one or more of the advantagesdescribed herein, and each of such variations and/or modifications isdeemed to be within the scope of the inventive embodiments describedherein. More generally, those skilled in the art will readily appreciatethat all parameters, dimensions, materials, and configurations describedherein are meant to be exemplary and that the actual parameters,dimensions, materials, and/or configurations will depend upon thespecific application or applications for which the inventive teachingsis/are used. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, many equivalentsto the specific inventive embodiments described herein. It is,therefore, to be understood that the foregoing embodiments are presentedby way of example only and that, within the scope of the appended claimsand equivalents thereto, inventive embodiments may be practicedotherwise than as specifically described and claimed. Inventiveembodiments of the present disclosure are directed to each individualfeature, system, article, material, kit, and/or method described herein.In addition, any combination of two or more such features, systems,articles, materials, kits, and/or methods, if such features, systems,articles, materials, kits, and/or methods are not mutually inconsistent,is included within the inventive scope of the present disclosure.

All definitions, as defined and used herein, should be understood tocontrol over dictionary definitions, definitions in documentsincorporated by reference, and/or ordinary meanings of the definedterms.

The indefinite articles “a” and “an,” as used herein in thespecification and in the claims, unless clearly indicated to thecontrary, should be understood to mean “at least one.”

The phrase “and/or,” as used herein in the specification and in theclaims, should be understood to mean “either or both” of the elements soconjoined, i.e., elements that are conjunctively present in some casesand disjunctively present in other cases. Multiple elements listed with“and/or” should be construed in the same fashion, i.e., “one or more” ofthe elements so conjoined. Other elements may optionally be presentother than the elements specifically identified by the “and/or” clause,whether related or unrelated to those elements specifically identified.Thus, as a non-limiting example, a reference to “A and/or B”, when usedin conjunction with open-ended language such as “comprising” can refer,in one embodiment, to A only (optionally including elements other thanB); in another embodiment, to B only (optionally including elementsother than A); in yet another embodiment, to both A and B (optionallyincluding other elements); etc.

As used herein in the specification and in the claims, “or” should beunderstood to have the same meaning as “and/or” as defined above. Forexample, when separating items in a list, “or” or “and/or” shall beinterpreted as being inclusive, i.e., the inclusion of at least one, butalso including more than one, of a number or list of elements, and,optionally, additional unlisted items. Only terms clearly indicated tothe contrary, such as “only one of” or “exactly one of,” or, when usedin the claims, “consisting of,” will refer to the inclusion of exactlyone element of a number or list of elements. In general, the term “or”as used herein shall only be interpreted as indicating exclusivealternatives (i.e. “one or the other but not both”) when preceded byterms of exclusivity, such as “either,” “one of,” “only one of,” or“exactly one of.” “Consisting essentially of,” when used in the claims,shall have its ordinary meaning as used in the field of patent law.

As used herein in the specification and in the claims, the phrase “atleast one,” in reference to a list of one or more elements, should beunderstood to mean at least one element selected from any one or more ofthe elements in the list of elements, but not necessarily including atleast one of each and every element specifically listed within the listof elements and not excluding any combinations of elements in the listof elements. This definition also allows that elements may optionally bepresent other than the elements specifically identified within the listof elements to which the phrase “at least one” refers, whether relatedor unrelated to those elements specifically identified. Thus, as anon-limiting example, “at least one of A and B” (or, equivalently, “atleast one of A or B,” or, equivalently “at least one of A and/or B”) canrefer, in one embodiment, to at least one, optionally including morethan one, A, with no B present (and optionally including elements otherthan B); in another embodiment, to at least one, optionally includingmore than one, B, with no A present (and optionally including elementsother than A); in yet another embodiment, to at least one, optionallyincluding more than one, A, and at least one, optionally including morethan one, B (and optionally including other elements); etc.

It should also be understood that, unless clearly indicated to thecontrary, in any methods claimed herein that include more than one stepor act, the order of the steps or acts of the method is not necessarilylimited to the order in which the steps or acts of the method arerecited.

In the claims, as well as in the specification above, all transitionalphrases such as “comprising,” “including,” “carrying,” “having,”“containing,” “involving,” “holding,” “composed of,” and the like are tobe understood to be open-ended, i.e., to mean including but not limitedto. Only the transitional phrases “consisting of” and “consistingessentially of” shall be closed or semi-closed transitional phrases,respectively, as set forth in the United States Patent Office Manual ofPatent Examining Procedures, Section 2111.03.

1. An abatement system having at least one removable misting arrayassembly, said abatement system comprising: an abatement chamber; afirst misting array assembly disposed in said abatement chamber, saidfirst misting array assembly extending through a first misting arrayopening in said abatement chamber; said first misting array assemblyincluding a first sealing piece sealingly engaging said first mistingarray opening, a first frame structure coupled to said first sealingpiece and disposed in said abatement chamber, and a first nozzle tubinghaving at least one first nozzle coupled thereto, said first nozzletubing coupled to said first sealing piece and said first framestructure and disposed in said abatement chamber; a first condensingcoil disposed in said abatement chamber downstream from said firstmisting array assembly; a second misting array assembly disposed in saidabatement chamber downstream from said first condensing coil, saidsecond misting array assembly extending through a second misting arrayopening in said abatement chamber and including a second sealing piecesealingly engaging said second misting array opening, a second framestructure coupled to said second sealing piece and disposed in saidabatement chamber, and a second nozzle tubing having at least one secondnozzle coupled thereto, said second nozzle tubing coupled to said secondsealing piece and said second frame structure and disposed in saidabatement chamber; a second condensing coil disposed in said abatementchamber downstream from said second misting array assembly; wherein atleast one of said first misting array assembly and said second mistingarray assembly is integrally removable from said abatement chamber; atemporary replacement piece sealingly engageble with at least one ofsaid first opening and said second opening when a respective of saidfirst misting array and said second misting array is removed from saidabatement chamber.
 2. The abatement system of claim 1 wherein said firstmisting array sealing piece includes a sealing plate engageable over anexterior portion of said first opening.
 3. The abatement system of claim2 wherein said temporary replacement piece is sealingly engageable withsaid first opening and includes a temporary sealing plate engageableover an exterior portion of said first opening.
 4. The abatement systemof claim 3 wherein said first misting array sealing piece furtherincludes a sealing piece extension extending from said sealing plate,said sealing piece extension removably receivable within said firstopening and in substantially conforming fit with said first opening. 5.The abatement system of claim 4 wherein said temporary replacement piecefurther includes a sealing piece extension extending from said sealingplate, said sealing piece extension removably receivable within saidfirst opening and in substantially conforming fit with said firstopening.
 6. The abatement system of claim 1 wherein both said firstmisting array assembly and said second misting array assembly areremovable from said abatement chamber.
 7. The abatement system of claim6 wherein said temporary replacement piece is sealingly engageable withboth said first opening and said second opening when a respective ofsaid first misting array and said second misting array is removed fromsaid abatement chamber.
 8. The abatement system of claim 6 wherein atleast one of said first misting array assembly and said second mistingarray assembly is slideably removable from said abatement chamber. 9.The abatement system of claim 1 further comprising a third misting arrayassembly disposed in said abatement chamber downstream from said firstmisting array assembly.
 10. The abatement system of claim 9 furthercomprising a third condensing coil disposed in said abatement chamberdownstream from said third misting array assembly, wherein said thirdmisting array assembly is disposed in said abatement chamber downstreamfrom said second condensing coil.
 11. The abatement system of claim 1wherein said temporary replacement piece is coupled to said first framestructure and engages said first opening when said first misting arrayis removed from said abatement chamber.
 12. An abatement system havingat least one removable misting array assembly, said abatement systemcomprising: an abatement chamber; a first misting array assemblydisposed in said abatement chamber, said first misting array assemblyextending through a first misting array opening in said abatementchamber; said first misting array assembly including a first sealingpiece sealingly engaging said first misting array opening, a first framestructure disposed in said abatement chamber, and a first nozzle tubinghaving at least one first nozzle coupled thereto, said first nozzledisposed in said abatement chamber; a first temporary replacement piececoupled to said first frame structure interiorly of said abatementchamber, wherein said first temporary replacement piece is sealinglyengageable with said first opening; a first condensing coil disposed insaid abatement chamber downstream from said first misting arrayassembly; wherein said first misting array assembly is removable fromsaid abatement chamber; and wherein when said first misting arrayassembly is removed from said abatement chamber said first temporaryreplacement piece engages said first opening.
 13. The abatement systemof claim 12 wherein said first misting array sealing piece includes asealing plate engageable over an exterior portion of said first opening.14. The abatement system of claim 13 wherein said first temporaryreplacement piece includes a temporary sealing plate engageable oversaid first opening.
 15. The abatement system of claim 12 furthercomprising a second misting array assembly disposed in said abatementchamber.
 16. A method of servicing or replacing a misting array assemblyof an abatement system while minimizing any interruption to saidabatement system, said method comprising: removing a first misting arrayassembly from an abatement chamber of said abatement system, therebycreating an opening between said abatement chamber and an exteriorenvironment surrounding said abatement chamber; covering said openingwith a temporary replacement piece; wherein said temporary replacementpiece seals said opening; and maintaining a second misting arrayassembly within said abatement chamber and operating at least saidsecond misting array assembly and a fan of said abatement system duringat least some of the time said opening is covered with said temporaryreplacement piece.
 17. The method of claim 16 further comprising thestep of uncovering said opening by moving said temporary replacementpiece and placing either said first misting array assembly or areplacement misting array assembly into said abatement chamber via saidopening.
 18. The method of claim 16 wherein at least said second mistingarray assembly and said fan of said abatement system are operated duringthe entire time said opening is covered with said temporary replacementpiece.
 19. The method of claim 16 wherein at least said second mistingarray assembly and said fan of said abatement system are operated duringthe entire time said first misting array is removed from said abatementchamber.
 20. The method of claim 16 wherein said temporary replacementpiece is coupled to said first misting array interiorly of saidabatement chamber.
 21. The method of claim 16 wherein said methodfurther comprises the step of detaching said misting array assembly fromsaid pollution abatement system prior to covering said opening with saidtemporary replacement piece.